Natech Accident Final
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Type
Natech Accident
Date
2011/03/11
Time
15:00
Status
Final

Units Involved

  1. Name
    Storage tanks 1
    Type
    Storage: Atmospheric storage tank
    Description
    The damaged tanks are:
    sulphur, asphalt, and gasoline tanks in the western refinery section.
  2. Name
    Storage tank 2
    Type
    Storage: Atmospheric storage tank
    Description
    smaller tank containing heavy oil.
  3. Name
    Pipe 1
    Type
    Auxiliary: Pipes and pipework
    Description
    Auxiliary to tanks for ship loading station
  4. Name
    Storage tanks 3
    Type
    Storage: Atmospheric storage tank
    Description
    - 65 m diameter oil tank in the eastern refinery section.
    - another tank in the same section, not specified
  5. Name
    Pipe 2
    Type
    Auxiliary: Pipes and pipework
    Description
    Auxiliary to tanks in the storage tank park
  6. Name
    Pipeline 3
    Type
    Transport: Pipeline
    Description
    Gate pipeline

Event Sequences

  1. Name
    Oil spill due to tank roofs damage
    Unit
    4. Storage tanks 3
    Description
    Bending of roof due to liquid sloshing and liquid spill
    Initiating EventCritical EventMajor Event
    Component (Non-structural): Roof damage
    In the eastern refinery section, the earthquake before the tsunami caused:
    - the roof of tank T-14 (it has a diameter of 65 m) was bent, resulting in damage to the roof seal.
    - one other tank also had minor roof damage.
    -
    Other: Other
    The damage of tank roofs led:
    - in tank T-14 oil being spilled from the damaged seal.
    - the other tank has minor spills.

    N.B. the spills were confined to the roofs.
  2. Name
    Oil spill due to tank floating
    Unit
    5. Pipe 2
    Description
    Floating tank impacting on pipe connection
    Substances Involved
    1. Name
      Crude oil
      Involved Quantity
      3900 m³
    Initiating EventCritical EventMajor Event
    Natural Hazard: Floating off of storage tanks / equipment
    The tsunami waters caused a smaller tank to float. Once the waters had receded the tank fell back on the ground, thereby breaking an attached pipe.
    Contributing Factors
    Measure: Instrument / control / monitoring devices: Inadequate
    Unfortunately, when the tsunami hit, a valve was open because tank filling was underway.
    Release: Liquid release to ground
    3,900 kl of oil were released.
    Release: Liquid release to water body
    -
  3. Name
    Gate pipeline collapse
    Unit
    6. Pipeline 3
    Initiating EventCritical EventMajor Event
    Component (Structural): Pipeline break / damage
    At the refinery’s gate a gasoline pipeline blocked entry. The pipe was supported by the iron gate; when the tsunami hit it fell off the pipe support, got dented and broke.
    Release: Liquid release to ground
    Gasoline spills from the broken pipe.
    -
  4. Name
    Oil spill from pipe
    Unit
    3. Pipe 1
    Substances Involved
    1. Name
      Crude oil
      Involved Quantity
      4400 m³
    Initiating EventCritical EventMajor Event
    Component (Structural): Pipeline break / damage
    The tsunami impact (or debris carried by the wave) damaged a pipe connected to a tank close to the shoreline used for loading ships.
    Release: Liquid release to ground
    4,400 kl of oil were released.
    Release: Liquid release to water body
    -
  5. Name
    Several tanks set on fire due to tanker truck
    Unit
    1. Storage tanks 1
    Substances Involved
    1. Name
      Asphalt
    2. Name
      Gasoline
    3. Name
      Sulphur
    Initiating EventCritical EventMajor Event
    Component (Structural): Pipeline break / damage
    The tsunami hit a tanker truck (it was loading hydrocarbons in the western refinery section) that fell over and a pipe broke near the truck.
    Release: Liquid release to ground
    Gasoline was then continuously released from the break.
    Contributing Factors
    Measure: Instrument / control / monitoring devices: Inadequate
    The valve on the tank-pipe connection was open as per normal operating procedures during tank filling. A significant amount of gasoline was released upon wave impact.
    Dispersion: Combustion products in air
    Sulphur combustion generated a cloud of toxic combustion products
    Fire: Pool fire
    Several hours after the tsunami, the gasoline released from the broken pipe ignited, due to unknown causes. Hypotheses about the ignition source range from sparking from the truck’s battery, static electricity, etc.
    Fire: Pool fire
    The fire propagates to nearby units containing liquid sulphur and asphalt. The tanker truck and gasoline, sulphur and asphalt were completely burned, due to the pipe fire. A gasoline tank was completely melted, others were partially melted and tilted. Fire spreading was facilitated by the damages caused by the tsunami on storage units

Emergency Response

Response Planning
Emergency response plan takes Natech events into consideration: Yes
Emergency response plan is sufficient in taking Natech events into consideration: No
Response Planning Activities
Unadequate on-site procedures contributed to the deaths due to the natural event.The procedures required that an inspection must be performed by the unit's responsible after the first earthquake aftershocks. When the tsunami hit the refinery the inspections where still ongoing.
Difficulties in Response to the Natural Hazard
Natech event prevents access of personnel to natural hazard affected area: Yes
Natech event prevents efficient operation of personnel in the natural hazard affected area: Yes
Response to the Natural Hazard
Shut-down occurred at a peak ground acceleration (PGA) of 0.25 g.
The earthquake sensors stopped measuring at 0.45 g; it is believed that the actual shaking forces exceeded this value.

At the industrial site the tsunami reached an height ranging between 2.5-3.5 m.
The fire department had more than 1000 staff and 2400 voluntary fire fighters. These resources were not enough to cope with the consequence of the earthquake and the tsunami. The police and military forces were also disposed. Vulontiers came from all over Japan to help. The national government fire bureau coordinated the activities and dispatched the teams to the various area in need.
Difficulties in Response to the Natech Event
Insufficient personnel and equipment to respond to both emergencies: Yes
Damage to lifelines (e.g. water, power, communication, transportation): Yes
Response Teams and Equipment Involved
  • On-site systems (e.g. sprinkler, water cannon)
  • On-site fire fighting team
  • Local fire fighting team
  • Regional / national fire fighting teams
Sheltering and Evacuation due to the Natech event
  • On-site evacuation
  • Off-site evacuation
Response to the Natech Event
Five hours after ignition, fire fighters have no access to the site due to:
- the smoke coming from the facility, and
- the debris created by the tsunami.

Communication was difficult. The debris carried by the tsunami made the road unusable. The company could not be reachable by phone. An helicopter of Japanese army was used to assess the extent of the fire.

On March 15, an access road was made, but the gate of the refinery was blocked by a gasoline pipeline. The on-site fire-fighting equipment could not be used due to tsunami damage. Hence, the fire-fighting equipment had to be brought into the refinery by hand.


The responders had to use heavy breathing apparatus to go into the JX refinery, because a significant amount of asphalt was released, as well as sulphur combustion products.

Some sulphur went underground and continued to burn there. Thus, the fire fighters had to drill holes in the ground to be able to inject water to quench the burning sulphur.

Due to ignition of sulphur and formation of toxic combustion smoke, the mayor issued an evacuation order in a 2 km radius around the refinery, thereby also delaying the intervention of the fire fighting teams.
Before accessing the site, a dosimeter measured a radiations coming from Fukushima. Radiation levels where 0.12 μSv, lower than the fixed limit to stop all activities: 0.3 μSv.

Foam was also used to block the access of oxygen to the spilled flammable materials, but the wind kept blowing the foam away.
Mobile pumps were set up at 4 locations in the western section to pump up river water.

Consequences

On-site Fatalities
4
On-site People At Risk
200
Human Health Impacts
Shortly before the arrival of the tsunami, most of the 200 employees succeed in finding a shelter and evacuate the site in the following night, but 4 of them and lost their life. They were caught in the tsunami wave during the inspection of the site units.
Environmental Zones Impacted
  • Inland (e.g. grassland, cropland, forest)
  • Shore (e.g. beach, dune, marsh land)
  • Off-shore (e.g. estuary, sea)
Environmental Impacts
Oil spots at the surface of the water reveal a massive pollution in the harbour.
At a nearby park, trees and grass were covered with thick crude oil from the accident.
On-site Material Losses
920 M USD
On-site Response and Remediation Costs
500 M USD
Economic Impacts
Crude loading and storage facilities restart two months after the event, but the refining units are severely damaged and production is resumed in 2012 (trial operation was started on Jan. 14, 2012).

The exploitation losses are evaluated at 920 millions Euro, of which more than 500 millions remediation costs.

The impact of tsunami dealt minor damages widespread on the whole refinery site:
-pipes and supports were bended or displaced
-storage tanks' basements were eroded by the water flow
-the tsunami damaged the catalytic cracking reactor's supports, which eventually collapsed due to another quake a few days later
-the quake damaged to heat exchangers' supports and foundations
-the shocks wrecked the chimneys
-the truck loading facility was destroyed by the tsunami and subsequent fire
-control room was completely submerged
-pipe racks were damaged due to debris
-the electric components were extensively damaged or destroyed: engines, pumps, control instrumentations, etc...

Damages and loss of production are significant, in the order of several hundred million of Euro. It took about one year to restore refinery's full production capacity.

Remedial Activities

Restoration Activities
In restoring the Sendai refinery, JX transferred its land shipment facilities to a place unsusceptible to the impact of tsunami and took measures to shield electrical systems from tsunami.
Moving forward, the company will push forward with work to fully restore shipment facilities and introduce new energy sources in the refinery.
The procedures to follow in case of earthquake have been changed after the tsunami.

Lessons Learned

Lessons Learned on Equipment
LPG tank braces were reinforced to enhance tank resistance to possible future earthquakes.
The doors and windows of the electrical system were elevated and all the instrumentation, equipments and control system were elevated to more than 4 m. All the sensitive documents, safety equipments and IT servers were elevated to more than 8 m.
Lessons Learned on Organisational Aspects
The shipment facilities were reinforced to 36 lanes to secure stable supply in the winter demand season and boosted its product stockpiles, and JX is set to further strengthen the refinery's to 52 lanes.
Lessons Learned on Emergency Response Aspects
The tsunami emergency response procedure is rewritten, removing the control round of the installations safety.
Responders need to be prepared for the consequence of a tsunami impact during response operation:
-responders should all be equipped with life jackets
-the use of rubber boats should be avoided due to the presence of sharp-edged debris
Responders were subjected to high stress:
-response activities could last for an undetermined lapse of time
-responders could worry for the safety of their own family members
-there was high concern for the radiation hazard coming from Fukushima

It is highly recommended a proper psychological training for emergency responders
ID: 21, Created: Bogdan DORNEANU, 2013-10-18 10:14:21 – Last Updated: Amos NECCI, 2016-07-11 11:18:13

Attachments

NoDescriptionFile Size
1.Japan Energy Brief No 12, March 2011 316.94KB
2.Krausmann, Cruz, 2013 700.65KB
3.OVERVIEW OF THE INDUSTRIAL ACCIDENTS CAUSED BY THE GREAT TOHOKU EARTHQUAKE AND TSUNAMI 6.64MB
4.Panorama des accidents industriels survenus lors du grand séisme du Tohoku (Japon – 11 mars 2011) 6.35MB